Trim panel and method of making the same



July 20, 1954 F. LYIJYNEN TRIM PANEL AND METHOD OF MAKING THE SAME Filed Sept. 12, 1950 2 Sheejts-Sheet l INVENOR.

m .9 y w July 20, 1954 F. LYIJ YNEN TRIM PANEL AND METHOD MAKING THE SAME Filed Sept. 12, 1950 2 Sheets-Sheet 2 INVENTOR. 6/ 4 5 /16. BY 7 Myra/i7 Patented July 20, 1954 TRIM PANEL AND METHOD OF MAKING THE SAME Fred Lyijynen, Detroit, Mich., assignor to Briggs Manufacturing Company, Detroit, Mich., a corporation of Michigan Application September 12, 1950, Serial No. 184,401

Claims.

This invention relates to ornamental panels and to a method of making the same, such panels being particularly useful as inner trim panels of various types of vehicle bodies, especially automobile bodies.

A trim panel to which the present invention is applicable preferably comprises a number of superimposed sheets or layers of material consolidated or bonded together under heat and pressure through the medium of a bonding agent composed of a thermosetting or thermoplastic resinous material. Inasmuch as it is usually desirable that the trim panel possess considerable rigidity or stiffness, the panel is preferably of laminated composite nature including a foundation sheet or board, which itself may be cornposed of one or a plurality of layers, and one or more relatively thin top or cover sheets which may be treated for design or ornamental purposes. A portion or all of the upper area of the panel may be upholstered, such as by employing a top fabric sheet and a padding layer interposed between the fabric and foundation.

In the use of a trim panel as interior trim for an automobile body it is necessary to provide means for fastening the panel to the inner frame structure of the body. Such fastening means is preferably of a nature to permit the panel to be readily removed and also should desirably be concealed when the panel is installed in place.

An object of the invention is to provide an improved trim panel of the foregoing character having means embodied in the panel at the underside thereof for removably supporting fastener devices by which the panel may be attached to a supporting structure.

A further object of the invention is to provide a method of making an ornamental or trim panel so as to incorporate therein fastener retaining means of such nature as to enable fastener devices to be removably attached thereto.

Another object of the invention is to provide a trim panel having metallic fastener means permanently embedded in the panel in such manner as to provide projecting portions suitable for attaching the panel to a foundation or supporting structure.

Still another object of the invention is to prochored in the foundation and, due to shrinkage of the latter after the curing operation, the tendency to foreshorten the metal strips will force the portions thereof exposed at the apertures in the bottom sheet through the apertures so as to provide loop portions suitable for use as fastener retaining means.

Other objects of this invention will appear in the following description and appended claims, reference being had to the accompanying drawings forming a part of this specification wherein like reference characters designate corresponding parts in the several views.

Fig. 1 is a top plan view of one form of trim panel constructed in accordance with the present invention.

Fig. 2 is an enlarged fragmentary isometric sectional view showing the elements of the panel of Fig. 1 arranged in superimposed relation immediately prior to the consolidation and bonding thereof together, the view being taken substantially in the direction of the arrows along the broken line 2-2 of Fig. 1 and a portion of the retainer strip and bottom layer being extended beyond the section line at the left.

Fig. 3 is an enlarged fragmentary section taken substantially through lines 33 of Fig. 1, looking in the direction of the arrows, showing a fastener device in assembled position.

Fig. 4 is a fragmentary section taken substantially through lines t4 of Fig. 3, looking in the direction of the arrows.

Fig. 5 is a fragmentary vertical section taken longitudinally of the retainer strip along the line 55 of Fig. 1, looking in the direction of the arrows.

Fig. 6 is a fragmentary vertical sectional view through the lower portion of a modified trim panel illustrating another embodiment of the present invention.

Figs. 7 and 3 are detail views illustrating the assembly of a fastener device to the kick panel shown in Fig. 6.

Fig. 9 is a detail view illustrating the manner in which the retainer strips in the embodiment of Figs. 6 through 8 may be assembled with the kick panel.

Fig. 10 is a fragmentary sectional view similar to Fig. 3, but showing another modification of a trim panel fastened directly to a metal body panel.

Fig. 11 is a fragmentary section taken substantially along the line HH of Fig. 10, looking in the direction of the arrows, showing the trim panel detached from the body panel.

It is to be understood that ti o present invention is not limited in its application to the details of construction and arrangement of parts illustrated in the accompanying drawings, since the invention is capable of other embodiments and of being practiced or carried out in ya ions Ways. Also it is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation.

For the purpose of illustrating one application of the present invention, there is illustrated in Figs. 1 through by way of example a trim panel of the type which may be used as a finish trim on the inside of an automobile body, such as on the door thereof. Trim panels of this type are frequently fabricated with a main upper part A, which may be covered with fabric or cloth having an underlying layer of padding, and a lower rather narrower part B, often termed a .kick panel, which may also be padded and covered, usually with a layer of more durable niaterial such as carpeting, imitation leather, or a layer of fabric of different color appearance or characteristic the upper covering layer.

In general the trim panel made in accordance with the present invention comprises a stiff Ioundationboard ill of any suitable composition, preferably of compressed fibrous stool; so as to have the requisite strength, rigidity and stiiiness.

Arranged in superimposed relation on the foundation ill are a relatively thick paper sheet H adjacent the foundation and a layer of padding or wadding E2 overlying the sheet 5 2. Overlying the padding 2 for the upper area A is a cover layer is preferably of cloth or abric material. The padding for the kick panel area B is covered with a suitable fabric mate "ial or sheet M, which as stated above may also comprise carpeting, imitation leather, or any other desired wear resistant material. The adjacent edges of the layers !3 and t l at the juncture of the panel areas A and B are separated by a gap 65 which may vary considerably in width and which is closed by means of an ornamental molding I6. The latter in the present instance comprises an outer thin metal strip in channel form carrying an insert strip ll treated or impregnated with a suitable bonding agent, such as a the mosetting reactive resinous substance. Preferably the molding it extends the full width of the panel, its ends being bent around the side edges of the panel and suitably secured to the backside there of by staples or other means.

Arranged beneath the foundation id is a bot tom layer l8 which maybe a relatively thin alpha-cellulose or fiber sheet, or if desired, a fabric layer. Before assembling the layer is with the foundation and cover materials, it is perforated to provide a number of vertically aligned apertures I9 spaced from top to bottom of the panel ad- 'jacent each of its opposite side edges, Figs. 1 and 2. Between the bottom layer It and the foundation ill, a thin fiat metal retainer strip 2i; is arranged adjacent each side edge of the panel.

The metal strips fill may comprises spring steel and are arranged to extend substantially the full height of the panel in line with the apertures 1'9. Thus with the various laminations and'metal strips 2t assembled as indicated in Fig. 2, the portions of each strip 2!] overlying the apertures 19 are exposed therethroughat the bottom of the panel.

Similar to the impregnated strip ll, the layers H and [8, as well as the foundation is if desired, especially along the underportions thereof overlying the strips are also treated or irrpregnated with a suitable bonding substance, preferably in the form of a thermoplastic or a partially polymerized or reacted therrnosetting resin. Any suitable resinous material may be used as a binder between the sheet laminations of the trim panels in the various embodiments herein shown and describe I prefer to use a phenolformaldehyde, a urea formaldehyde, or melamine reshi or combinations thereof which may be converted into a varnish by the use of suitable solvents in order to facilitate application to the laminations. This resinous material is only in .a partially or "eacted condition at the time the larninations are introduced into the press. Accordingly in fabrication of the panel, its various ins.tions, including the strips 26 and moi-ding .6 are formed to their desired shapes and arranged in superimposed relation as shown in Fig. 2. The laminations are than subjected to heat and pressr e between the heated dies or platens of a suit-dole press, whereby the final curing or polymerization of the resin is completed and the laininations consolidated and bonded together.

In the present instance the laminations are in part secured or bonded together especially along ornamental lines define-{l by relatively deep ind ntations or grooves, such as the vertical grooves 2i the U-shapecl groove in the upper area A of the the horizontal grooves 23 in the kick B. In th s regard, the die or platen of tie press which confronts the face of the panel is suitably ribbed to emboss the indentations or grooves 2i, and 23 into the compressible panel layers and is also provided with a suitable die portion adapted to overlie the full length of the molding it so as to force the latter into the panel Alon the grooves or compressed areas Bi, 22 and 23 and beneath the molding it, the resinous bondin material in the sheet ii and insert strip il' will flow into the compressed Wedding or padding layer i2 and will penetrate to extent the top covering layers l3 and i l. "Lie temperature and ore is regulated the press operation so that the resinous material is cured or brought to a final stage of reaction or nerization. As a result these layers are consolidated bonded permanently to each other and to the molding l and foundation ill at the compressed localities. By this structure, the panel layers are securely and permanently bonded together upon completion of the curing or reaction of the resin, while substantial areas of e panel between the molding 6 and grooves 52 22 and 23 remain uncompressed, giving the panel as a whole a soft upholstered effect. The arrangement of th grooves or indentations is purely for illustrative purposes. It

will be apparent that the lines or localities at which the laminaticns are pressed and bonded together may be varied as to configuration or otherwise in order to produce any desired pattern 01' design.

The face of the die or platen which engages the bottom layer 5 ll during the press operation is plane so as to press substantially uniformly against the entire area of the bottom layer l5. Thus while the upper panel. layers are bonded together along the grooves 2 i 22 and and under the molding it, the resin in the treated under surface of the foundation to and bottom layer It is reacted so as to bond these layers permanently to each other and to the interposed metal strips 20.

When the finished panel is removed from the press and cooled, it will shrink to a certain extent. As a result of shrinkage of the panel in the direction of the length of the strips 20, forces are exerted tending to shorten these strips, causing portions Etc thereof to bulge downwardly through the apertures l 9, Fig. 5.

As shown in Figs. 3 and 4, the projectin or bulging portions 26a of the metal strips provide, in accordance with the present invention, retainer means for the removable attachment thereto of projecting fastener devices C. Any suitable fastener device having a base which may be slid underneath the loop-like retainer portion Eta may be used. In the present instance the fastener device C comprises a wedge-shaped portion as projecting outwardly at right angles to the plane of the bottom of the trim panel. This portion 2 3 terminates in a laterally bent portion which is return bent to provide a base 25 adapted to be inserted beneath the loop-like portion 25 a and frictionally held in position between this portion and the adjacent bottom surface of the foundation sheet. The portions 24 and 25 of the fastener device C are split at 21 throughout most of their length to permit a degree of expansion and contraction when the fastener device is forced through a hole in the frame structure of the vehicle body in order to attach the panel thereto.

From the foregoing it will be seen that the trim panel in the embodiment of Figs. 1 to 5 inclusive is provided with molded-in metal strips 20 along the edges thereof which produce at suitable intervals in their length projecting fastener holding portions Etc. The bottoms of these portions lie very close to the plane of the bottom of the sheet is and hence do not produce objectionable projections on the bottom of the panel. With this construction the panels may be readily stacked together flat for the purposes of shipment. When the panel is ready to be installed upon the vehicle body, the fastener devices C may be readily and quickly attached to the retainer portions 20a. The panel is then assembled on the vehicle door or body frame by forcing all of the wedge-shaped projecting ends 24 of the fasteners through correspondingly located apertures in the door or body frame.

Another embodiment of the invention is illustrated in Figs. 6-5 in application with a modified trim panel wherein the lower kick panel portion comparable to the area B of Fig. 1 comprises two superimposed separately formed sections connected together by fastener elements. The trim panel in this embodiment comprises a foundation sheet or board 29 fabricated in the manner previously described and having the upper area thereof covered as for example by a layer of paddin as and an outer trim layer 3| of fabric or other suitable material. The fabric layer 3| and the wadding or padding layer 30 are permanently joined to the foundation board 29 by means of a suitable binder, such as a thermoplastic or thermosetting resinous substance, this being preferably acccmplished in a press under heat and pressure .to effect consolidation of these layers or laminations. The lower portion of the founda tion board 29 is thereafter covered by means of a kick panel section 1-32 which is separately formed and may comprise two or more layers of fibrous material consolidated together through the medium of a thermoplastic or thermosetting resinous substance.

The kick panel section 32 illustrated in Fig. 6,

by way of example comprises outer and inner laminations 32a and 32b preferably in the form of white wood pulp or other fine grain cellulosic material and is secured to the foundation 29 by a number of metal fasteners 33, discussed below, suitably located as for example along the top, side, and bottom edges of the panel 32. The upper edge of the kick panel section 32 extends into abutting relation with the lower edge of the covering material 3s, 3l, whereat the horizontal juncture between these upper and lower portions is covered by a horizontal metal molding strip 34 secured to the foundation board 29 by fasteners 35 projecting through the foundation and clinched over at the back thereof.

The fastener elements 33 for attaching the kick panel section 32 to the foundation board 29 are carried by short sheet metal retainer strips or clips 36 firmly anchored at opposite ends between the layers or laminations 32a and 32b, Fig. 7. Each retainer strip 36 is assembled prior to consolidation of the sheets 32a, 322) by inserting its opposite ends 36a through spaced slits 31 in the sheet 3229 in a manner to expose an intermediate portion 36b of the retainer strip at the back of the sheet 322). The outer sheet 32a is then superimposed on the sheet 32b and the two sheets are consolidated by heat and pressure so as to anchor the end portions 3ta firmly therebetween. As in the first embodiment above described, the intermediate portion 35b of the retainer strip will bulge outwardly due to the shrinkage or contraction of the sheets 32a and 32b upon cooling thereof after removal from the press. Thus the bulged portions 36b of the retainer strips will be spaced rearwardly from the face of the sheet 32b sufiiciently to permit attachment thereto of the aforesaid fastener elements 33. Each fastener element 33 comprises a metal piece having a base 33c insertable beneath the retainer portion 36b and a portion projecting at right angles thereto which may be inserted through an appropriate slot 38 in the foundation 29 and then bent or clinched down at 33b so as to anchor the kick panel section 32 firmly in place on the foundation board 25.

By forming the kick panel section 32 in the embodiment of Figs. 6 through 8 separately from the foundation board 29 and the remainder of the trim panel, it is possible to utilize inexpensive dies and permit considerable savings in the cost of production of the trim panel. l'he several layers used in fabricating the kick panel section 32 may first be consolidated together between fiat heated dies of inexpensive nature, during which operation the retainer strips 36 are united to the sheets 32a, 3222. Thereafter while the consolidated layers are still in heated and pliable condition, the panel section 32 may be introduced between inexpensive hard wood dies and suitable grooves or indentations 39 pressed into the sheet to give the desired ornamental appearance or pattern to the kick panel.

Where the retainer strips 35 for the fasteners 33 are located adjacent the edges of the kick panel section 32, they may if desired be installed in the manner illustrated in Fig. 9. In this instance the edge of the sheet 32b is slit inwardly along spaced lines 40 and the intermediate edge portion M is bent forward to permit insertion of the fastener strip 36. The latter is inserted through the spaced slits 40 so that the intermediate portion 36b is exposed at the back of the sheet. Consolidation of the sheets 32a and 32b together firmly anchors the ends 36a in 7 position between the sheets. Upon contraction of the latter, the intermediate portion 3% will bulge outwardly to permit attachment thereto of a fastener element Where desired, the end. portions oi the fastener strip are provid with notches 9 which 102i i the strip against displacement between the consolid tecl Referring to the embodiment illustrated in Figs. 10 and. 11, a fragmentary por n of a panel is shown which in the present may serve 0' a i trim the inside of a We two layers grain cellniosie inateiial. These yers are con. soiidatezi together through the ediurn of thermoplastic or ther. setting ren, as in manner previously 0 serif therewith are rstener retai' p iored hetween the sheets ta and 53b anti an erinerliate sowed or looplike portion 3%. The eonstruoti ner in which the dated with the iaininations of 43 may the same tiesor neetioit 8, or Fig. 9.

The retainer st e spaced sizing the side and bottom edges of tie panel section in positions for the remova -16 attaoi'; thereto of any suitable type fas ener In ti e pres nt embod ment, bell. teners are ut ed, eaoh having a ease or which may slit. underneath the loopn bulged retainer portion and ha .1. 5 yieldable wedge-shapes. leg warziiy at right angle" to the plane or 3 tom of the panel sect the section 'y be installed directly on a supporting re, such as a;. inner metal door panel 10, having ape" l' iii o twarrl ions ii} for insertion snugly therethrough or the projecting" fastener legs flat ret poses a en n one iaoe e panel, and shrin. i la 'th to to hue he po tiens of A ward from face of the panel.

2. In the method of making a panel, the steps of placing spring metal strip between two superimposed sheets in line with spaoetl apertures in one of said sheets exposing portions of the a a panel comprising 3 metal strip rough a pinne oi layers spaced the teps of treating at ith incompletely with with her under 0 complete t the g the layers enoes Cited in the file of this p tent UNITED STATES PATEVTS Name Date m 3 om'mfls ia, J.i1 4. setup .2511. 2, 1334: 3. 18,462 he i age l Feb 20 1 3 P g l a i,9:2, i A fan Dlessei sent. 4 1934 O y 4,028,992 Piaoo 52 28 19% 4 u 2,l.50,e53 R 14 939 {A 2 1 1941 2,03) 3 944 9 5 aisles? 194s 2,5813%5 N52 

1. IN THE METHOD OF MAKING A PANEL, THE STEPS OF BONDING TOGETHER A PLURALITY OF SUPERIMPOSED LAYERS ADAPTED TO BE SHRUNK AND AN INTERPOSED FLAT RETAINER STRIP HAVING PORTIONS THEREOF EXPOSED AT OPENINGS IN ONE FACE OF THE PANEL, AND 